Polymer system used as a repairing and maintenance solution

ABSTRACT

A slow curing polymer system used as a repairing and maintenance solution in covering potholes. The polymer system comprises of a hydrophobic barrier coat in the form of a polymer film that is formed due to a polymer reaction that happens when a polymer mixture is applied or poured on to the surface of the potholes. The polymer mixture is time cured to maintain a liquid state to fill all voids and crevices prior to hardening and eventually attains self-leveling with the applied surface and is referred to as hydrophobic barrier coat. Further, an additional polymer foam can be applied on the polymer hydrophobic base coat that provides for filling of the void an adequate adhesion on upper surface of the polymer foam to adhere the applique. The complete polymer system fills and covers one or more potholes as a repairing and maintenance solution.

FIELD OF INVENTION

The present invention relates to repairing and maintenance solution and more particularly to a polymer system that is used to repair and maintain potholes, larger cracks, or road seams.

BACKGROUND

Existing road maintenance and repair of potholes and larger cracks or road seams, is often accomplished utilizing Hot Mix Asphalt (HMA), Warm Mix Asphalt (WMA), or Cold Asphalt patching material. The HMA and WMA process often involves heavy equipment, CDL drivers, and multiple highway, asphalt, or concrete workers. Furthermore, the availability of HMA and WMA is limited to the months in which local asphalt plants are open.

With many existing repair solutions, compaction is a key element in achieving a long lasting, durable repair. Compaction is also a key variable, one that is affected by tools, equipment, aggregate type and size, and the personnel performing the repair. In many instances one pothole will form next to an existing, previously repaired one, starting a pothole “cluster” that often results in sections of roadway needing to be cut and new asphalt being applied down to the base stone material. This applies to all three types of common repair material and processes: HMA; WMA; Cold Patch.

Water and the freeze-thaw cycle often perpetuate asphalt failure. Any cracks, seams, or a pothole, where water can penetrate, is likely to be the cause of larger and more numerous potholes, delamination, or other surface failure.

From an occupational health point, it is noted that there is a direct correlation between certain types of cancer and those working with asphalt on a regular basis. Hence, there is a need for a novel material and process improvement as well as enhancement that result in a significantly longer lasting, more consistent, and less expensive, repair.

SUMMARY

The present invention is related to a slow curing polymer system used as a repairing and maintenance solution for covering a pothole, wherein the polymer system comprises of a seal-coat in the form of a polymer film that is formed within a time span due to a polymer reaction and an applique adhering to the upper surface of the polymer film that covers the potholes.

Additionally, the polymer film can adhere a polymer foam on the top surface, and the polymer foam comprises of a hydrophobic barrier between ground moisture originating at the base of an exposed pothole. Further, an adequate adhesion is provided on the upper surface of the polymer foam to adhere the applique on the polymer foam. There are several inherent advantages in using the polymer system and the advantages are listed below:

-   -   Prudent risk management—Potholes present a liability, whether it         is slip and fall or property damage to most parties. Appliques         can be available on-site and require no heavy equipment, asphalt         supply, or compaction, and can be applied in any weather.     -   There is no adverse health exposure to personnel working with         appliques. As there are no fumes, dust, or other health         concerns.     -   Appliques may be cut to size on site and provide for a         consistency in form and function unachievable with materials         compacted on site.     -   Larger appliques can be manufactured to address larger sections         of roadways or even driveways (working on custom trucks and roll         system much like carpet or artificial turf).     -   In the case of pothole clusters, a larger applique may be         applied to bridge the individual pothole repairs thus creating         one seamless repair of the area. This is opposed to continuing         to repair individual potholes and creating an even larger         cluster with even more failure points.     -   A precast applique can be manufactured to meet specific         requirement of various organizations such as Department of         Transportation within much tighter tolerances. An example would         be meeting specific coefficient of friction or hardness         requirements.     -   An organization can keep several appliques on trucks for quick,         on-the-spot, repairs. Other objects and advantages of the         embodiments herein will become readily apparent from the         following detailed description taken in conjunction with the         accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING(S)

FIG. 1, according to an embodiment of the present invention, illustrates a polymer system used for repairing the potholes.

FIGS. 2 and 3, according to an embodiment of the present invention, illustrate an applique that adheres to the polymer foam to cover the potholes.

FIG. 4, according to an embodiment of the present invention, illustrates equipment used for pre-manufacturing an applique.

FIG. 5, according to an embodiment of the present invention, illustrates application equipment used for blending a plurality of liquids.

DETAILED DESCRIPTION

In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The term “potholes” shall subsequently represent a defect within, or traversing through, a course of a bituminous mixture or cementitious mixture and shall include craters, cracks, seams, and any combination thereof.

The following detailed description is therefore not to be taken in a limiting sense. A slow curing polymer system that provides adequate adhesion between a substrate and a designated applique, which provides water resistance both during and after the process of curing of a polymer system while repairing potholes. Further, the polymer system provides a sufficient time span, identified as “cure time”, from which the polymer reaction is initiated until the polymer system is cured and the polymer may be manipulated into a film that will provide the properties of adhesion and water resistance. The cure time is further defined as a change in state, or morphology, represented by the time span for which the liquid state of the polymers undergo a chemical reaction upon which, approaching the completion of chemical reaction, the polymers become solid, semi-solid, or elastomeric in characteristic.

In the proposed invention, the cured polymer system provides a water barrier that may prevent the transmission of moisture through such barrier. In an exemplary embodiment, the surface of which the water barrier is applied prohibits the transition of moisture to a subsequent surface.

The polymer system may incorporate chemicals that are known to absorb and/or react with existing substrate moisture and the chemicals are commercially known as “moisture scavengers”. The polymer systems providing an adequate water barrier shall be comprised of a liquid NCO-functional isocyanate that may chemically react with a liquid amine-functional compound to form a polymeric film.

One such embodiment of the invention is specific to cavities and fissures that are formed within asphalt road surfaces commonly referred to as “potholes”. The polymer system, as such, may be further referenced as “hydrophobic barrier coat”. The hydrophobic barrier coat shall provide adequate adhesion to a substrate, and provide a water barrier, may also be employed to provide adhesion and water barrier to the inner surfaces of the pothole. In this embodiment, the water barrier shall inhibit the moisture transmission of ground water as may be present within or around the inner surface of the pothole.

The polymer system, or seal-coat, as manipulated into a film within the inner surfaces of a pothole, shall act as bonding surface to subsequent additions of polymer materials. An exemplary embodiment of the bonding surface may include the addition of polymeric foam. The foam is applied as a multi-component liquid, commonly referred to as “plural component” whereas a minimum of two reactive liquids are plurally blended at or near the point of evacuation of suitable application equipment.

Referring to FIG. 1, illustrates a polymer system 100 used for filling the potholes. In an embodiment, a polymer reaction occurs when a polymer mixture is poured into a cavity or fissure. Further, the polymer mixture is a timed reaction as to maintain a liquid state to fill all voids and crevices prior to rising In an exemplary embodiment, the specific polymer system 100 may comprise an NCO-functional liquid isocyanate compound that is chemically reacted with a liquid amine-functional compound to form a polymer foam 103. In an embodiment, a sufficient time span from which the polymer reaction is initiated to a time that the polymer foam 103 rises shall be sufficient to maintain a liquid or semi-liquid morphology for which the material can flow freely into cracks and fissures. The phenomena of pooling of liquid or semi-liquid morphology of the polymer system are referred to as “self-leveling”.

In an embodiment, a load bearing, high density, timed-rise poured (could be sprayed) foam 103 enters the pothole as a liquid and over top of the hydrophobic barrier coat. The delay allows the foam to maintain its' liquid state and become self leveling. In its' liquid state it also fills all voids and crevices prior to expanding, thereby stabilizing the underlying base material. After approximately 30 seconds, the foam 103 begins to form and expand, filling all voids and further stabilizing the underlying area. Upon final rise time of about 5 minutes the applique 104 is applied on the foam 103. There can be several other methods of creating a level surface with the expanding foam. One is a partial containment approach where the applique 104 is placed over the foam before it fully rises and leaves a ½′ gap around the perimeter for the rising foam to expand out. Further, the excess foam is removed off around the perimeter and compresses the applique 104 containing an adhesive polymer to be level with the surrounding repair area. Another, more likely approach, is that the polymer system 100 allows the foam to expand uncontrolled and 2-4″ above the pothole or seam. Further, a custom designed tool can be used to remove the top of the foam off to the same level as the surrounding asphalt or concrete. In an embodiment, the polymer foam 103 comprises of a hydrophobic barrier 102 between ground moisture originating at the base of an exposed pothole and the polymer foam base. The polymer mixture flows into the potholes through predrilled holes 108 in the applique (104) that allow penetration of the hydrophobic edge seal 106. The hydrophobic edge seal 106 bonds the hydrophobic barrier coat 102 of the polymer foam 103 with the applique 104 by providing adequate adhesion 106 on upper surface of the polymer foam 103. In an embodiment, the applique 104 can be pre-manufactured in the form of a thin slab and can be sealed along the perimeter and the outer surface of the polymer foam 103 that adequately covers surface dimensions of one or more potholes 101. In an embodiment, the applique 104 is made-up of a material that has elongation and hardness properties and is embedded within the polymer system 100. For example, the applique 104 can be made-up of an Aluminium Silicate material. The applique (104) is provided with a Ultra-Violet (UV) resistant coating (107) that provides color stability to the finished repair area. The hydrophobic edge seal provides for a water tight seal as well as providing for lateral stability and shear resistance under typical road use. Another embodiment includes addition of a polymeric foam over the hydrophobic barrier coat of the polymer system. In such embodiment, the hydrophobic barrier coat provides adequate adhesion to a substrate, a water barrier, and an adequate bonding surface for subsequent polymeric materials, which may employ such subsequent polymeric materials in the form of polymeric foam. In such embodiment, a polymeric foam shall be comprised of no less than two components whereas one component is comprised of a liquid containing an NCO-functional isocyanate that shall be blended with a second liquid component comprised of a reactant upon which, the blending of no less than these two components shall result in the polymeric formation of a foam. The foam formation may produce an open cellular construct or may produce a closed cellular construct. In an exemplary embodiment, a closed cellular construct is desirable within the spirit of this invention.

Referring to FIGS. 2 and 3, illustrates an applique that adheres to the polymer foam to cover the potholes. In an embodiment, the polymer system supports additional applique or pre-manufactured or prefabricated exposed course. In such embodiment, the hydrophobic barrier coat that provides adequate adhesion to a substrate, a water barrier, and an adequate bonding surface for subsequent polymeric materials, as such may employ a polymeric foam of closed cell construct that can adhere a placard or an applique of polymeric construct. In such embodiment, an applique of polymer construct comprises of a polymer system identical to or similar to that of the hydrophobic barrier coat. Entrained within the polymeric construct of the applique shall be a dispersed volume of aggregate. In such embodiment, the aggregate shall be comprised of particles for which the mean particle size shall be no less than 1/16 of an inch upon its length.

Such aggregate shall maintain a chemical classification of alumina silicate, though one skilled in the art may use a variety of aggregates without deviating from the spirit of the invention. Furthermore, in this embodiment, an applique may be created by separate process by which a volumetric ratio of said aggregate may be dispersed within a specific volume of blended liquid polymer to create slurry which shall be further molded or cast into a shape. It is found that slurry comprised of aggregate and polymer system identical to, or similar to, the hydrophobic barrier coat in specific volumetric proportions, induces porosity within the cured formation of slurry.

In an exemplary format, a volume of five parts of aggregate may be dispersed within a volume of one part of liquid polymer blend. For example, using a polymer such as the previously defined hydrophobic barrier coat for which the creation of the cured polymer requires the blending of equal volumes of two separate liquids. This example may require 5 gallons of aggregate to be dispersed within the one gallon of the blended volume of hydrophobic barrier coat polymers. One gallon of hydrophobic barrier coat polymer is derived by blending ½ gallon of hydrophobic barrier coat polymer part-A with ½ gallon of hydrophobic barrier coat polymer Part-B. Furthermore, upon blending of aggregate with hydrophobic barrier coat polymer part-A and with hydrophobic barrier coat polymer part-B, and prior to the conclusion of the previously defined cure time of the hydrophobic barrier coat, the combined volume, or any partial volume thereof, shall be transferred into a mold of any predefined dimension, and sculpted, compressed, pushed, raked, or anywise shaped into desirable dimensions.

Such techniques may include the compression of the slurry between flat or textured rigid surfaces such that, upon curing of the polymer, shall retain the flat or textured imprint of those surfaces. Other techniques may include the temporary deposition of slurry among or between films of plastic. In this technique, the slurry is sandwiched between two or more sheets of plastic film. The plastic film may contain an agent, or coating, which inhibits the adhesion of the plastic film to the slurry, such that the plastic film may later be removed. Further, the slurry may be temporarily deposited between two sheets of plastic film and can be further manipulated by applying pressure, by means of rigid flat plates, or textured plates, or by roller, or by anywise means for which such manipulation shall cause the slurry to flatten among its upper or lower surface.

By means of any adaptation of this technique, a slurry that has been temporarily cast upon a surface, of plastic film or otherwise, and further manipulated into a flattened state, and further waited sufficient time for which the polymer that comprises a portion of the slurry has cured, can be further used as an applique, or covering of any other existing surface. In this embodiment, the flattened cast, and cured, slurry shall be used as an applique for which may then be bonded to the upper surface of the foam within a pothole as previously defined. Furthermore, the applique may be constructed with perforations on or about its perimeter which may transcend the upper and lower fascia of the applique. A polymer system identical to, or similar to that of the hydrophobic barrier coat, may be applied around or about the applique to provide a means of bonding the applique to the foam, bonding the applique about or to a surface which contains the pothole, or to any surface thereof. In the presence of perforations upon or about the perimeter, and which may transcend the upper and lower fascia of the applique, may also provide additional bonding surface for which the hydrophobic barrier coat applied about the perimeter of the applique may provide sufficient bonding.

In another embodiment, the application of the foam may be substituted with the slurry. In such embodiment, the hydrophobic barrier coat that provides adequate adhesion to a substrate, a water barrier, and an adequate bonding surface for subsequent polymeric materials, as such that may employ a polymer dispersed aggregate, or slurry of previously defined construct, shall be deposited within a pothole, as previously defined, a top of such hydrophobic barrier coat.

In such embodiment, the slurry shall be transferred to, or within, a pothole within such time as to not to exceed the cure time of the polymer that comprises a portion of the slurry construct. As such, the slurry may be manipulated as to fill the pothole to create an even, or about even, top surface. Further, the slurry may be manipulated by compression, or compaction, within the pothole. Within this exemplary embodiment, such slurry transferred into a pothole within a time span as to not to exceed its cure time shall retain the liquid characteristic of its liquid polymer constituent and retains an ability to flow. As such, the slurry may naturally flow fully, or partially, into complex contours within the pothole cavity without manual or mechanical manipulation.

A specific volumetric ratio variations of the slurry construct is identified for which, in the cured state of the slurry, shall provide advantageous responses to environmental stimuli. It is found that a construction of slurry that consists of a volume of aggregate not more than three times more than the total volume of polymer shall be water permeation resistant. In the field of application, a water permeation resistant applique may be utilized for occurrences in which a pothole, or other pavement-like defect shall be repaired in a manner as to resist ground water, rain water, sewage water, or similar, from penetration of the repair. This means of repair may occur in environmentally protected areas for which roadway contaminants, such as petroleum by products, fuels, and oils may become entrained in rainwater. Maintaining a water permeation resistant repair of road defects will reduce the seepage of such contaminated water runoff into environmentally protected waterways and lands. Inversely, such theater of application may inhibit contaminated water from arising out of a contaminated area and onto a surface. These occurrences may exist for applications intended to hermetically seal, or separate, contaminates from entering a roadway or walkway.

Likewise, it is found that the construction of the slurry that consists of a volume of aggregate not less than three times more than the total volume of polymer shall be water permeation non-resistant. In this embodiment, the slurry that has cured into a state that has filled a pothole, or a slurry that has cured into a state such as that as an applique, shall promote water permeation, or water dissipation, throughout its surface and construct thereof. In the field of application, a water permeable applique may be utilized for occurrences in which a pothole or other pavement-like defect shall be repaired in a manner as to dissipate pooling or surface water. This means of repair may occur upon road surfaces for which the contour, or unevenness, of the road surface collects a pooling of surface water; such pooling may induce, or accelerate, the formation of potholes. Such pooling may also induce vehicular hydroplaning, a common source of vehicle accidents and personal injury. In such occurrences, a water dissipative material shall allow pooling water to seep through the applique and dissipate both laterally and through its construct. Inversely, such theater of application may promote underlying water to evaporate through its construct. These occurrences may exist for applications for which entrapment of moisture beneath an applique is not beneficial.

Referring to FIG. 4, illustrates equipment used for pre-manufacturing the applique with specific coefficient of friction or hardness requirements as required by specific application. A pre-manufactured asphalt-like applique utilizing a polymer binder system impregnated with up-cycled materials such as coal slag, fiberglass microfibers, and other potential additives enhances physical properties of the complete material system. The material is pre-cast to designated thicknesses such as ¼″ or ½″ and in a multitude of shapes and sizes and the pre-manufactured appliques can then be provided to various entities or organizations.

Referring to FIG. 5, illustrates application equipment used for mixing multi-component reactive liquids.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the appended claims. Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the invention with modifications. However, all such modifications are deemed to be within the scope of the claims. 

What is claimed is:
 1. A slow curing polymer system used as a repairing and maintenance solution for covering at least one pothole, wherein said polymer system comprises of: a) a hydrophobic barrier coat in the form of a polymer film formed after a polymer reaction is initiated and a curing time has elapsed for said polymer reaction; b) an additional polymer foam that is applied on the surface of said hydrophobic barrier coat to provide adequate adhesion for a substrate; c) an additional polymeric construct adhering to said hydrophobic barrier coat or said polymer foam to cover said at least one pothole; d) an additional adhesive bonding agent and sealer to seal said polymeric construct to said polymer system to cover said at least one pothole.
 2. The polymer system as claimed in claim 1, wherein said polymer reaction occurs when a plurality of liquid compounds chemically react to form said polymer film.
 3. The polymer system as claimed in claim 2, wherein said polymer film associated properties comprises of: providing adequate adhesion for said substrate, providing a water barrier for the inner surface of said at least one pothole, providing an adequate bonding surface for subsequent polymeric materials.
 4. 5. The polymer system as claimed in claim 1, wherein said polymer foam is formed by blending a first liquid component with a second liquid component that acts as a reactant.
 6. The polymer system as claimed in claim 4, wherein said polymer foam can be in the form of an open cellular construct or a closed cellular construct.
 7. The polymer system as claimed in claim 1, wherein said polymeric construct can be in the form of an applique, a placard, a pre-manufactured or a prefabricated exposed course that adheres to said polymer film or said polymer foam.
 8. The polymer system as claimed in claim 6, wherein said polymeric construct is entrained with dispersed volume of aggregate that is comprised of particles for which the mean particle size is greater than 1/16 of an inch length of said polymeric construct.
 9. The polymer system as claimed in claim 1, wherein said polymeric construct is provided with perforations around the perimeter of said polymeric construct for applying said polymer foam or said polymer film that acts as a bonding agent or a sealer to adhere said polymeric construct to said polymer system.
 10. The polymer system as claimed in claim 6, wherein said applique can be created from a process in which a volumetric ratio of an aggregate may be dispersed within a specific volume of blended liquid polymer to form a slurry, which can be further molded or casted into a shape.
 11. The polymer system as claimed in claim 9, wherein said slurry can be used as said applique after temporarily placing said slurry in between an upper plastic film and a lower plastic film and flattening said slurry by applying pressure through rigid flat plates, textured plates, roller, or the like.
 12. The polymer system as claimed in claim 9, wherein said slurry can flow as a liquid into said at least one pothole until said slurry has elapsed said curing time. 